MANUAL AND MAINTENANCE MANUAL BENDING BRAKES...

ROPER WHITNEYOF ROCKFORD, INC.

2833 HUFFMAN BLVDROCKFORD, ILLINOIS 61103

815/962-3011815/962-2227 FAX

INSTALLATION, OPERATION,AND MAINTENANCE

MANUALVersion 2.2

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FLOOR MODELMANUAL BENDING BRAKES

MODELS 816, 1018 AND 1016

Have you considered?

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Why not upgrade your handbrake with the new powered backgauging systemfrom Roper Whitney of Rockford?

The EZ Gage kit is available for field installation on existing 8-foot and 10-footRoper Connecticut floor brakes.

Contact your Roper Whitney of Rockford dealer orrepresentative for details.

ROPER WHITNEYOF ROCKFORD, INC.

2833 HUFFMAN BLVDROCKFORD, ILLINOIS 61103

815/962-3011815/962-2227 FAX

��

FLOOR MODELMANUAL BENDING BRAKES

Page i

INSTALLATION, OPERATION,AND MAINTENANCE

MANUALVersion 2.1

FOR 16-18 GUAGE MATERIAL* All steel construction — no castings* Heavy tie rods for minimum deflection* Removeable bending bar and angle* Adjustable apron hinges* Positive rear material gauge adjustment

* Positive clamping pressure adjustment* Apron stop rod for repeat bends* Replaceable bushings and hinge pin* Long handles for extra leverage* Work support angle bar for full capacity 1-inch minimum flange* Improved leg design for lighter weight

ABOUT THIS MANUAL

Manual Brake Installation, Operation, and Maintenance Manual

Page ii

This manual contains information on the Roper Whitney Company line floor-mounted manual bending brakes for 16- to 18-gauge material.

The contents include a machine description, safety precautions, instructions forinstallation, adjustment, operation, maintenance, and repair; and a parts listproviding a listing of repair parts.

The manual is written with the experienced sheet metal operator in mind. Theoperator should be familiar with tooling, machine setup, materials, work methods,and setup and finished product inspection. Experienced operators not familiar withthe equipment covered will be able to set up and run the machine from the manual.Novice operators can be trained from the manual, but additional instruction maybe needed.

It is strongly recommended that anyone using the equipment covered read themanual thoroughly, and understand the material presented.

The setup and operating instructions are based on the intended application of themachine as defined by Roper Whitney. Use of the machine for other applicationsis not precluded, but use for purposes specifically excluded is not recommended,and may void warranty provisions.

Material in this manual is confidential, and Roper Whitney reserves all rights in thisregard.

If you have questions concerning usage or operating techniques not covered bythis manual, or if you encounter maintenance or repair problems, Roper Whitneyfield service and product support personnel can provide you with assistance.Before calling, please obtain the following information:

* machine type* machine serial number* description of application you wish to attempt* description of problem you have encountered

Contact:

Roper Whitney of Rockford, Inc.2833 Huffman BoulevardRockford, Illinois 61103Phone: 815/962-3011Fax: 815/962-2227

CONTENT

ADDITIONALASSISTANCE

INFORMATIONUSAGE

AUDIENCE

TABLE OF CONTENTS


Page iii

About This Manual ii

Warranty Provisions iv

Section 1: Safety Precautions 1

General Precautions ........................................................................................................................... 1Safety Precautions During Operation ................................................................................................ 2

Section 2: Machine Description 3

Section 3: Specifications 4

Section 4: Receiving and Installation 5

Receiving ........................................................................................................................................... 5Unloading ........................................................................................................................................... 5Unpacking .......................................................................................................................................... 5Site Preparation.................................................................................................................................. 6Setting the Brake ............................................................................................................................... 7Leveling the Brake ............................................................................................................................. 7Anchoring the Brake .......................................................................................................................... 7Installing the Counterweights ............................................................................................................ 8

Section 5: Setup 9

Setting Clamping Pressure ................................................................................................................. 9Adjusting for Material Thickness ..................................................................................................... 10Setting Up for Narrow or Offset Bends ........................................................................................... 11Setting Up the Bend Angle Stop ...................................................................................................... 12Setting Up the Optional Rear Material Stops .................................................................................. 12

Section 6: Operation 13

General Instructions ......................................................................................................................... 13Clamping the Material ...................................................................................................................... 13Bending the Material ........................................................................................................................ 14Bending of Multiple Thicknesses ..................................................................................................... 14Hemming .......................................................................................................................................... 15

Section 7: Periodic Maintenance 16

Lubricating Rotating Components ................................................................................................... 16Lubricating Sliding Components ...................................................................................................... 16Lubricating Adjusting Nuts and Screws........................................................................................... 16Adjusting the Clamping Collars ....................................................................................................... 17

Section 8: Maintenance Adjustments 18

Brake Crowning Adjustments .......................................................................................................... 18Preloading Adjustment ..................................................................................................................... 20

Section 9: Repair Parts List 23


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LIMITED WARRANTY

All new Roper Whitney tools and machines are warranted, to the originalpurchaser for use, to be free of defects in material and workmanship for a periodof one year from purchaser's date of purchase. Roper Whitney, at its option, willrepair, replace, or refund the purchase price of any tool or machine which failswithin the warranty period, and is found upon examination by Roper Whitney, tobe defective in material or workmanship, or both. This warranty does not coverfailures attributable to improper use or maintenance , exceeding rated capacity,alteration, accident, or normal wear of moving parts. Accessories, controls, andcomponents not manufactured by Roper Whitney Company are excluded from thiswarranty. For services on such parts, refer to the applicable manufacturers'warranties.

There is no other express warranty to the extent permitted by law. Any and allimplied warranties, including merchantability and fitness for a particular purposeare excluded; and implied warranties not excluded are limited in duration to oneyear from the date of purchase. Incidental and consequential damages areexpressly excluded from the remedies available to purchaser, and the remediesprovided in this warranty shall be exclusive to the extent permitted by law. (Note:Some states do not allow limitations on how long an implied warranty lasts, or theexclusion or limitation of incidental or consequential damages; so the foregoinglimitations and exclusions may not apply to you. This warranty gives you specificlegal rights, and you may also have other rights which vary from state to state.)

Purchaser must give written notice to Roper Whitney Company, at the addressshown below, of any warranty claims, within thirty days after failure, and if soinstructed, return to Roper Whitney Company the parts to be replaced or repaired,with all transportation charges prepaid by purchaser. Replacement parts will beinvoiced to purchaser, with credit issued for parts covered by this warranty, andfreight thereon. Removal and reinstallation of replacement parts shall be at thepurchaser's expense.

Return of the warranty registration card furnished with the product purchased isnecessary to obtain warranty covereage thereon. The card must be fully com-pleted, signed by the purchaser, and, if applicable, signed by the distributor. Returnthe registration card to:

Roper Whitney of Rockford, Inc.2833 Huffman BoulevardRockford, Illinois 61103

COVERAGE

REGISTRATION

WARRANTYCLAIMS

EXCLUSIONS

SECTION 1SAFETY PRECAUTIONS


Page 1

Before using the Roper Whitney manual brake, carefully read and fully understandthe safety precautions outlined in this section. GENERAL PRECAUTIONS pertain tothe general workplace, and to the attitudes and work habits you bring to the job.SAFETY PRECAUTIONS DURING OPERATION pertain to work on the brake, and arerepeated in other areas of the manual where they pertain.

Do not consider this section to be all-inclusive on the subject of safety. It isintended to be a general guide to safety practices as they pertain to the machinescovered by this manual. No set of guidelines can substitute for a common-sense,informed, proficient, safety-conscious attitude on your part.

Notify management or supervision whenever you feel there is any hazard involvingthe equipment or the performance of your job.

Never permit untrained individuals to operate this equipment without closesupervision. Be sure you know and understand the task at hand, and the hazardsassociated with it.

Observe and follow safety instructions for your work area. Pay special attentionto posted warnings, and warning labels on the equipment. Do not place speedabove safety.

Wear appropriate clothing. Loose or hanging clothing or jewelry, finger rings, etc.can be hazardous. Use the appropriate safety equipment, such as eye and hearingprotection, and safety-toe shoes. If gloves are worn to protect from cuts, be surethey are snug-fitting and not likely to be snagged by moving equipment.

Keep the work area neat and orderly. Be sure it is well lit, that extra tools are putaway, trash and refuse are in the proper containers, and dirt, chips or debris havebeen removed from the working areas of the machine. Be sure the floor area isclean and dry, and that extension cords and similar trip hazards have been removed.

Use the proper tools for the job. Inspect them before use to see that they are in goodworking condition. Replace broken or defective tools and equipment.

Use only approved cleaning materials: do not use explosive or flammable liquidsto clean the machine. Discard used cleaning materials in the appropriate contain-ers.

Do not use compressed air to clean debris, chips, dirt, or grit from the machine,or from your clothing. Remove chips and grit from the machine with a suitablebrush; never with your hands.

GENERALPRECAUTIONS


Page 2

Do not attempt to operate the brake in excess of its rated capacity. Do not attemptto form wire, nails, rods or pipe on the machine.

Avoid any pinch points created by movement of the machine's components.

Exercise care around the bending apron counterweights. Stand clear of the endsof the brake during the bend cycle or whenever the bending apron is moved. Donot loosen the set screws securing the counterweight rods while the bending apronis in the vertical position.

SAFETYPRECAUTIONSDURINGOPERATION

WARNING

SERIOUS INJURY MAY OCCUR

The counterweight and rod can drop suddenly through the holder.

Always use the apron lift handles to apply the bending force. Under no circum-stances use the counterweight rods for leverage. Failure to heed this warning cancause personal injury or damage to the counterweight rods. Always stand clear ofthe apron lift handle travel arc during the bend cycle to avoid being struck by thehandles.

WARNING

SERIOUS INJURY MAY OCCUR

Avoid pinch points created by the clamping and bending components.

Always stand clear of clamping handles. If the brake has not been properly adjustedfor material thickness; clamping action on one end of the brake may cause theopposite clamping handle to snap forward due to the twisting stress created on theupper beam. (this can also indicate that the clamping collars need adjustment.Refer to Section VII, Periodic Maintenance.)When opening the upper beammake sure the handles are moved to the horizontal position to avoid accidentalforward movement of the handles caused by the weight of the upper beam.

If you observe unusual noises or vibrations during machine operation, check themachine condition immediately. Do not attempt to operate the equipment furtheruntil the causes of unusual behavior have been found and corrected.


Page 3

SECTION 2MACHINE DESCRIPTION

Roper Whitney floor mounted manual bending brakes are precision machines foruse in bending mild steel and other sheet metals, including aluminum, brass,bronze, copper, duralumin; lead, monel metal, silver, carbon and stainless steelwithin rated capacity.

The brakes are rated to form a 1-inch minimum wide flange over entire length ofbrake on a single thickness of material of the rated gauge capacity with work anglesupport installed. Bending capacities are reduced by four (4) gauges when theapron work support is removed.

The machines are essentially identical in construction, varying only in length orcapacity. Major components are shown in Figure 1.

Fabricated of sturdy steel plate with appropriate gussets, braces and trusses; threebasic longitudinal members (upper-beam, lower-beam and bending leaf/apron)control the clamping pressure and stress incurred in overcoming the yield strengthof the material being formed. Provisions for adjusting clamping force andtensioning of the longitudinal members are incorporated in the design of thebending brakes.

Figure 1. Major Components of the Floor Mounted Manual Bending Brakes.

COUNTERWEIGHT

LOWER BEAM AND MACHINE BED

CLAMPING LEVER

COUNTERWEIGHT

CLAMPING LEVER

BENDING APRON

UPPER BEAM AND CLAMP

TENSIONING MEMBERS

TENSIONING MEMBERS


Page 4

SECTION 3SPECIFICATIONS

Feature Model Model Model816 1016 1018

Bed Length 97 in. 121 in. 121 in.

Capacity on mild steel, 1-in. flange With bending bar and angle in place 16 Ga. 16 Ga. 18 Ga. With bending angle removed 20 Ga. 20 Ga. 22 Ga. With bending bar and angle removed 24 Ga. 24 Ga. 26 Ga.

Minimum Reverse Bend (bending bar and angle removed) 1/4 in. 1/4 in. 1/4 in.

Maximum lift of beam 1-5/8 in. 2-1/4 in. 1-5/8 in.

Front to Rear Adjustment of Beam 1-1/8 in. 1-3/8 in. 1-1/8 in.

Approximate Shipping Weight 1640 lbs. 2660 lbs. 2200 lbs.

Packing heavy wood skids and blocking with a plastic cover


Page 5

RECEIVING When you receive your bending brake, check immediately for obvious damage,which may have occurred during transit, to the skidding material or to the brakeitself. Also check to see that all material listed on the bill of lading is present.

Since Roper Whitney equipment is normally sold F.O.B., factory in Rockford, IL,our responsibility for transit damage ceases when the transportation companysigns the bill of lading indicating it has received the items listed in good condition.

Report discovered damage or shortages to the carrier. Make a notation on thedelivery waybill, and have the delivering driver sign it, acknowledging the damageor shortage.

Submit claims for repair or replacement to the carrier; include any extra shippingcharges. Notify Roper Whitney Company promptly of any damage or shortages.

If you discover concealed damages or shortages after the carrier has departed, youmay still file a claim for concealed damage. This should be done as quickly aspossible. Again, notify Roper Whitney Company promptly of such damages orshortages.

The brake is shipped on a skid of 3" x 6" wood timbers. It is secured to this skidwith four (4) carriage bolts, which should remain secured while the machine isunloaded and moved about. The skid and brake may be moved using a suitable forklift.

UNPACKING The two counterweight arms (rods) and their counterweights are mountedseparately on the wooden skid for shipment. Remove these from the skit and setto one side.

SECTION 4RECEIVING AND INSTALLATION

UNLOADING

WARNING

WHEN IN MOTION, THE SKIDDED BRAKE MAY BE TOP HEAVY

When lifting or moving the skidded brake with a forklift, secure the brake laterally tothe forklift.

WARNING

THE COUNTERWEIGHT ARMS AND COUNTERWEIGHTS AREHEAVY

Use care when removing them from the skid to avoid injury.

The clamping handles at each end of the brake are wrapped and wired in the downposition to prevent damage and to prevent the handles from being used to movethe brake. Remove the wires and wrapping.

Wooden blocks are positioned between the upper and lower beam jaws to preventdamage during shipment. Lift the clamping handles and remove the blocks.

The bending leaf (apron), is wired to the center truss stud of the lower beam toprevent movement during transit. Remove the wire.

Remove the four (4) carriage bolts, nuts, and washers securing the brake to theskidding. DO NOT REMOVE THE BRAKE FROM THE SKID AT THISTIME.


Page 6

WARNING AND CAUTION

SERIOUS INJURY CAN RESULT OR THE BENDING BRAKE CAN BEDAMAGED

Do not operate the brake on the skid. The brake must be attached to the floor. Themachine is topheavy and can tip if not securely anchored. The skid does not provide

a suitable anchoring platform.

SITEPREPARATION

The brake must be placed on a firm floor which does not sag and which does nothave any "spring" to it. The floor must be generally level, with no twisting orunevenness in the surface. The floor must also be capable of accepting 1/2-inch lagscrews or bolts for the purpose of securing the brake.

There must be adequate area around the brake for free movement of the operatorand the handling of large sheets of metal. Allow 4 to 6 feet behind the brake, 6 to8 feet in front of the brake, and 3 feet on either end of the brake.

To move the brake off the skid, and to its mounting position, use an overhead craneor a fork lift with the forks above the brake. If a fork lift is used, secure a liftinghook on the lift forks. Pass a sling under brake and secure each end on the liftinghook as shown in Figure 2.

CAUTION

THE BENDING BRAKE CAN BE DAMAGED

Do not move the brake using lift truck forks directly under any machine members.


Page 7

Using the overhead crane, lift the brake from the skid and place it in its desiredlocation. Be sure the brake is properly balanced.

SETTING THEBRAKE

WARNING

THE BRAKE TENDS TO BE TOPHEAVY AND CAN TWISTIN THE SLING

Use care when moving the brake from the skid to avoid injury.

Figure 2. The proper lifting method for moving the brake.

Raise the upper beam to its maximum height using the eccentric lifting levers. (SeeFigure Place an accurate spirit-level on the bed at each end of the bed bar.

Shim under the legs of the brake until the bed bar shows the machine is level front-to-rear. This will remove any twist from the bed. Side-to-side leveling is notnecessary to proper operation of the brake.

Anchor the leveled brake to the floor using 1/2-inch lag screws or bolts throughthe leg mounting holes. Tighten securely, making sure pressure is exerted on theleveling shims.

LEVELING THEBRAKE

ANCHORING THEBRAKE


Page 8

INSTALLING THECOUNTER-WEIGHTS

Have an assistant raise the bending apron to the horizontal position, and hold it inthat position while the counterweights are installed.

Install a counterweight in the mounting hole in each end of the bending apron.Adjust the counterweights so that they balance the bending aparon in thehorizontal position.

Tighten two set screws securely on each counterweight shaft.

WARNING

THE COUNTERWEIGHTS ARE HEAVY

Use care when installing the counterweights to avoid injury. Be sure the set screwsare tightened enough so the counterweights will not drop when the bending apron is

returned to the vertical position.

Be sure the gauge thickness of the material to be formed to is within the ratedcapacity of the machine. Then adjust clamping pressure as follows:

1. At each end of the brake, loosen both toggle pin lock nuts slightly beforebeginning adjustment (see Figure 3).

2. Place small sample pieces of the material to be formed between the upperbeam radius bar and the bed at each end of the machine. Clamp in position.

3. At each end of the machine, tighten the lower toggle pin lock nut againstthe toggle anchor just enough to hold material firmly when the clamp-ing lever is against the forward stop (see Figure 3).


SECTION 5SETUP

The machine has been adjusted and pretensioned at the factory. Set-up adjust-ments are for clamping pressure, material thickness, setting up for narrow or offsetbends, setting bend angle control, and setting up of the optional rear material stops.

Excessive clamping pressure is not required or desirable. It has a tendency tocounteract the normal preloading adjustments and may interfere with obtainingstraight and uniform bends. Use only enough clamping pressure to keep thematerial from slipping.

SETTINGCLAMPINGPRESSURE

Figure 3. Clamping Pressure Adjustments.

Page 9

LOWER TOGGLE PIN LOCK NUT

TOGGLE ANCHOR

UPPER TOGGLE PIN LOCK NUT

CLAMPING LEVER

TOGGLE ASSEMBLY


4. At each end of the machine, tighten upper toggle pin lock nut againstthe toggle anchor (see Figure 3).

5. At each end of the machine, pull the clamping lever forward against thestop. Each end should require equal effort. Adjust one end, if necessary,according to the general procedure above.

Under normal circumstances, clearance between the apron edge and the upperbeam radius bar should be approximately (2) times the material thickness for 16ga. mild steel. For lighter gauge material, less clearance is required. One and a half(1-1/2) times material thickness is usually sufficient. Soft material, such asaluminum, may be formed with a clearance equal to the material thickness.

SETTINGCLAMPINGPRESSURE

ADJUSTING FORMATERIALTHICKNESS

Figure 4. Material Thickness and Angle Adjustments.

Make the adjustment as follows:

1. With the upper beam lowered to the normal operating position, but notclamped tightly against the bed, loosen the thickness adjustment clampingscrews located on both ends of the brake (see Figure 4).

2. Raise the apron to the 90-degree position.

Page 10

CLAMPING LEVER

CAUTION

THE BENDING BRAKE CAN BE DAMAGED

Clearance must never be less than the material thickness.

THICKNESS ADJUSTMENTSCREW

THICKNESS ADJUSTMENTCLAMPING SCREW

ANGLE STOP STUD

ANGLE STOP COLLAR

ANGLE STOP COLLARSET SCREW

ANGLE STOP ROD

Remove the bending reinforcing angle and the bending bar as follows:

1. Support the bending reinforcing angle and remove retaining screws.Withdraw the angle from the machine (see Figure 5).

2. Support the bending bar and remove retaining screws. Withdraw thebar from the machine (see Figure 5).

3. After the bending operation is complete, be sure to replace the removedcomponents, attaching them with the retaining screws. Tighten the screwssecurely.


3. Move the upper beam forward or back until proper clearance is achievedby turning the thickness adjusting screw located at rear of the leg bracketon each end of the machine (see Figure 4). Final adjustment must alwaysbe toward the front of the brake to remove backlash from the adjustingscrews.

4. Retighten the clamping screw on each end of the machine (see Figure 4).

It is sometimes necessary to remove the bending reinforcing angle to make narrowor offset bends. In extreme conditions, it may also be necessary to remove thebending bar. The bending bar is made of tough, wear resistant material to protectthe edge of the apron and should be removed only when absolutely necessary tomake tight reverse bends.

Removing the bending reinforcing angle reduces capacity by four (4) gauges. Therated 16 ga. capacity is reduced to 20 ga. capacity. Removing both the bendingreinforcing angle and the bending bar reduces the 16 ga. capacity to 24 gaugecapacity.

ADJUSTING FORMATERIALTHICKNESS

SETTING UPFOR NARROWOR OFFSETBENDS

Figure 5. Removal of the Bending Reinforcing Angle and the BendingBar.

Page 11

BENDING BAR(LOCATED BEHIND THEBENDING REINFORCING

ANGLE)

BENDING REINFORCINGANGLE


SETTING UP THEBEND ANGLESTOP

The bend angle stop can be adjusted for multiple or precision bends.Adjust theangle stop as follows:

1. Loosen the angle stop collar set screw and move the angle stop collar outtoward the end of the angle stop rod. (See Figure 4.)

2. Have an assistant move the apron to the desired position and hold it whileyou adjust the collar. Be sure to take spring-back into account when settingthe angle.

3. Move the angle stop collar against the angle stop stud and tighten the anglestop collar set screw to retain it in that position.

SETTING UP THEOPTIONAL REARMATERIALSTOPS

For repeat operations involving deeper bends, it may be useful to use the optionalrear material stops.

Figure 6. Installing and Adjusting the Optional Rear Material Stops.

Install and adjust the rear material stops as follows:

1. At each end of the machine, insert a threaded stop rod. Secure the stop rodusing the stop rod lock nuts (see Figure 6).

2. Adjust a stop nut on each stop rod to the desired position. Be sure that bothstop nuts are the same distance from the front of the machine. (Anglularbends not perpendicular to the material edges can be made by offsettingone stop nut from the other. This will reduce the overall width which canbe bent.) (See Figure 6.)

3. Lock each stop nut in place using a stop lock nut (see Figure

Page 12

STOP LOCKNUT

STOP NUTSTOP ROD

LOCK NUTS

STOP ROD


SECTION 6OPERATION

GENERALINSTRUCTIONS

Operation of the brake is entirely manual, and the operator has full control of theoperation at all times.

Do not attempt to operate the brake in excess of its rated capacity. Do not attemptto form wire, nails, rods or pipe on the machine.

If you are bending large sheets of material which are difficult to handle, you maywish to use an assistant to help in loading, clamping, and bending.

If you observe unusual noises or vibrations during machine operation, check themachine condition immediately. Do not attempt to operate the equipment furtheruntil the causes of unusual behavior have been found and corrected.

CLAMPING THEMATERIAL

Insert the material to be bent under the upper beam clamping mechanism, lining upboth sides so they are even with the upper beam. Position short pieces of materialin the center of the brake to equalize strain during bending.

Clamp the material by lowering the upper beam with the clamping levers.

If the brake has not been properly adjusted for material thickness; clamping actionon one end of the brake may cause the opposite clamping handle to snap forwarddue to the twisting stress created on the upper beam.

When opening the upper beam make sure the handles are moved to the horizontalposition to avoid accidental forward movement of the handles caused by the weightof the upper beam.

WARNING

PINCH POINTS CAN CAUSE SERIOUS INJURY

Avoid any pinch pointscreated by movement of the machine's components.

WARNING

THE UPPER BEAM CLAMPING MECHANISM CAN CAUSE SERIOUSINJURY

Always stand clear of clamping handles. Do not place fingers near or under the upperbeam.

Page 13


BENDING THEMATERIAL

Bend the material to the desired bend angle using the apron lift handles to applythe bending force. Under no circumstances use the counterweight rods forleverage.

If the material being bent is long and protrudes from the machine, lift it during thebending operation to avoid creases or crimps caused by material weight.

BENDING OFMULTIPLETHICKNESSES

To avoid adjusting for every piece on a run of parts, do all the single-thicknessbending operations first, then adjust and do the multiple thickness bending.

Never bend against hems or seams until an adjustment has been made to compensatefor the clamping of multiple thicknesses of material. Never bend against hems or seamsuntil the upper beam is set back for clearance of the multiple thicknesses of material. SeeSETUP, SECTION 5, for adjustment instructions.

CAUTION

MACHINE COMPONENTS CAN BE DAMAGED

Failure to compensate for multiple thicknesses of material may result in breakage ofthe clamping mechanism.

Failure to set the upper beam back for extra clearance may result in indentations onthe upper beam jaw.

CAUTION

THE COUNTERWEIGHT RODS CAN BE DAMAGED

Using the counterweight rods to apply bending force can damage them.

WARNING

THE COUNTERWEIGHTS AND CLAMPING HANDLESCAN CAUSE INJURY

Always stand clear of the ends of the brake during the bend cycle.Always stand clear of the apron lift handle travel arc during the bend cycle.

Page 14


HEMMING Hemming is the most difficult operation to control accurately on a hand brake.

Hemming creates pressure loads on the machine different than those created byregular bending, and optimum results will not be obtained using the same machinepreloading for both hemming and bending.

In factory tests, closing 24 Ga. material all the way along was done easily with nochange in the preloading settings used for bending. 22 Ga. material was open about1/32 inch in the middle and hems in 20 Ga. had an opening in the middle of justunder 1/16 inch under like conditions.

If you must have tight hems in material heavier than 24 Ga., do all of the bendingfirst, adjust the machine for hemming, and close the hems in a second operation.

Hemming is traditionally done by making a maximum bend of about 135 degreesand flattening it between beam and bed by lowering the clamping levers.

This approach may require additional preloading in order to close the hem tightlyat the center. Increase the preload by tightening the upper beam tensioningadjusting nut (see Figure 9).

It also requires reducing clamping pressure to allow for multiple thicknesses ofmaterial. Reduce clamping pressure by slackening the lower toggle pin adjustingnut and tightening the upper toggle pin adjusting nut (See Figure 10).

Remove the workpiece from the machine after bending. Close the machine byclamping the beam down on the bed with the clamping levers. Place the workpieceon the front surface of the upper beam. Swing the apron up and close the hem bysqueezing the workpiece between the machined surface of the apron and the upperfront surface of the radius bar.

This may feel awkward at first, especially if you are accustomed to hemming in thetraditional manner, but it will get easier with practice and the end result is farsuperior to the traditional way.

It may be necessary to move the upper beam 1/8" to 3/16" to the rear to allowclearances for the hem between apron and front of beam. See SETUP, SECTION5, for adjustment instructions.

HEMMING......THETRADITIONALMETHOD

HEMMING......ANOTHER WAY

Page 15


Page 16

Grease fittings are provided for rotating components where wear may occur. Usea medium weight bearing grease, such as SAE No. 30, and grease weekly whenthe brake is being used. The rotating components are: the clamping lever assembly,the apron hinge assembly (2 fittings), and the toggle pin bushing. One set of thesecomponents is found on each end of the machine. Location of these fittings isshown in Figure 7.

Grease sliding components weekly as well, using general purpose grease, or equivalent.These components include the clamping pin bushings and the slots in which they ride (seeFigure 7).

The upper and lower beam tensioning screws (see Figure 8) are under heavy load andmust not be allowed to run dry. Keep them lubricated with an anti-sieze compound.

If the machine is frequently readjusted, the lower apron tensioning lock nut (see FigureU), and upper beam tensioning lock nut, and the lower beam tensioning locknuts (seeFigure 8), they should be kept lubricated with an anti-sieze compound.

Figure 7. Grease Lubrication Points on the Brake

CLAMPING LEVER ASSEMBLYAPRON HINGE ASSEMBLY(2 FITTINGS)

TOGGLE PIN BUSHING

SECTION 7PERIODIC MAINTENANCE

LUBRICATING....ROTATINGCOMPONENTS

....SLIDINGCOMPONENTS

....ADJUSTINGNUTSAND SCREWS

SLIDE PIN BUSHINGS


Page 17

ADJUSTING THECLAMPINGCOLLARS

The retaining system used to hold the clamping levers in the open position requireperiodic adjustment. Adjust the collars using the following procedure:

Figure 8. Adjusting the Clamping Lever Collars

1. Slightly loosen the set screws retaining the clamping collars on each endof the machine. Set screws should be loose enough to permit adjustmentof the clamping collars, but not so loose as to permit loss of position onthe clamping collars when the clamping levers are moved.

2. Tighten the clamping collars by turning them clockwise, until you areunable to move the clamping levers to clamp material.

3. Back off the clamping collars by turning them counterclockwise until youcan move the clamping levers to clamp material. The collars are properlyadjusted when one lever can be unclamped, and the lever at the oppositeend of the machine remains clamped. It may require several adjustmentsat each end of the machine to achieve the proper tension. During theseadjustments, be sure the set screws remain tight enough to prevent loss ofposition by the clamping collars when the clamping levers are moved.

4. When the collars are properly adjusted, tighten the set screws securely toretain the clamping collars in place.

CLAMPING LEVER

CLAMPING COLLARSET SCREW(ON O.D. OFCLAMPINGCOLLAR)

CLAMPINGCOLLAR

BRONZETHRUSTWASHER

LOCKWASHER

STEEL FLAT WASHER(MODEL 1016 ONLY)


Page 18

SECTION 8MAINTENANCE ADJUSTMENTS

When the machine does not bend properly, it is sometimes necessary to readjustthe crown on the beams. Use the following procedure:

1. Relieve all tension on the upper beam tensioning nuts and on the upperbeam tensioning screw (see Figure 9).

2. Lower the upper beam onto the bed. Loosen lower toggle pin adjustingnut until there is 1/4-in. of space between bottom of the toggle anchor andthe lower toggle pin adjusting nut (see Figure 10).

3. Adjust the upper beam and lower beam tensioning screws finger tight;and then tighten each with a wrench approximately one full turn (five flats)(see Figure 9).

4. Adjust the upper beam tensioning nuts finger tight, and then tighteneach with a wrench approximately one full turn (five flats) (see Figure 9).

5. When looking from the rear of the brake, the upper beam and the bedshould be in contact at the center and showing a crack of light at each end(see Figure 11). If less light shows at one end, loosen the rear floor bolt atthat end and shim under the leg until the light shows evenly at both ends.

6. Tighten the lower toggle pin adjusting nut against the bottom of the toggleanchor (see Figure 11).

BRAKECROWNINGADJUSTMENTS

Figure 9. Upper Beam and Bed Tensioning Components.

UPPER BEAMTENSIONING NUTS

LOWER BEAMTENSIONING NUT

LOWER BEAMTENSIONING SCREW

UPPER BEAMTENSIONING SCREW


Page 19

Figure 10. Upper Beam Clamp Adjusting Components.

LOWER TOGGLE PINADJUSTING NUT

Figure 11. Proper Clearance Between the Upper Beam Clamp and theBed.

BEAM

BED

THE BEAM AND THE BED MUST BE INCONTACT AT THE CENTER OF THE MACHINE

EXAGGERATED VIEW OF GAP AT EACH ENDOF THE MACHINE

THE GAP MUST BE EQUAL AT BOTH ENDS

BRAKECROWNINGADJUSTMENTS

TOGGLE ANCHOR


Page 20

Once the brake crown has been set, the brake must be adjusted to produce straightbending and a uniform radius. Follow the procedure below:

1. Loosen the apron tensioning nuts on the apron, (see Figure 12) and theupper and lower beam tensioning nuts (see Figure 9).

On the Model 1016 brake also loosen the apron stiffener adjusting nutlocated behind the lower apron tensioning adjusting nut (see Figure 12).

2. Loosen the upper and lower beam tensioning screws (see Figure 9).

3. Raise the upper beam to its maximum open height

4. Check the top edge of apron in relation to the top surface of the bed. Thetop edge of apron must be 1/64-in. below the top surface of the bed at eachend. If not, loosen the hinge bolts and adjust the apron up or down usingthe apron jack screws (see Figure 13). After the apron edge is adjusted tothe proper position, be sure to retighten the hinge bolts.

5. Tighten the apron stiffener adjusting nut until the apron edge is 1/32-in.above the bed edge at the center (see Figure 12). The apron edge shouldremain 1/64-in. below the bed edge at both ends.

6. Adjust the upper and lower beam tensioning screws finger tight; and thentighten each with a wrench approximately one full turn (five flats) (seeFigure 8).

PRELOADINGADJUSTMENT

Figure 12. Preloading Adjusting Components.

APRON STIFFENER ADJUSTINGNUT

(MODEL 1016 ONLY)

APRON TENSIONING ADJUSTINGNUT


Page 21

PRELOADINGADJUSTMENT

7. Tighten lower beam tensioning nut until the edge of the bed is 1/64"above the top edge of the apron at the center (see Figure 9). The edges ofthe bed and apron will then be parallel from end to end, with the edge ofthe bed 1/64" higher than the apron edge.

On the Model 1016 brake tighten the apron stiffener strap bolt locatedbehind the lower apron tensioning nut until the horizontal gap be-tween the bed and apron is slightly greater in the center than at the ends (seeFigure 12). It may then be necessary to back off the lower apron tensioningnut slightly to maintain the bed 1/64-in. higher than the edge of the apron.

8. Tighten upper and lower beam tensioning nuts finger tight; and then, usinga wrench, tighten each from 1/4 to 1/2 turn.

The bending brake is now properly adjusted for its rated gauge capacity in mildsteel.

HINGE BOLTS

APRON JACKSCREWS

Figure 13. Apron Adjusting Components.

9

133

65

7,8

17

12

11

10

15

14

1

4

216

A


Figure 14. Exploded View of Replacement PartsPage 22


Page 23

SECTION 9REPAIR PARTS

The table below identifies parts which may be replaced on the Roper Whitney manualbending brake. Parts may be ordered directly from your Roper Whitney distributor.If you have no distributor in your area, you may order the parts directly from thecompany. Common hardware items such as screws and nuts may be purchased locally,so long as the items purchased are of equivalent quality to those originally supplied withthe machine.

The Ref. No. column is keyed to the exploded view on the facing page. The PartNumber columns provide part numbers for replacement parts for each model brakecovered by this manual. The Part Name column provides a short descriptive name foreach replacement part. The Qty. column identifies the quantity required for replace-ment.

Part Number

Ref. Model Model ModelNo. 1018 1016 816 Part Name Qty.

1 257020009 257020003 257020006 Apron Assembly 12 757030029 757030029 757030013 Bending Bar 13 613012131 Screw, Flat Head, 5/16-18 by 3/4 213 613012131 613012131 Screw, Flat Head, 5/16-18 by 3/4 174 757180028 757180028 757180012 Bending Angle 15 657012641 657012641 Cap Screw, Hex Head, 1/2-13 by 1-3/4 115 657012641 Cap Screw, Hex Head, 1/2-13 by 1-3/4 96 679033107 679033107 Washer, Lock, 1/2-inch 116 679033107 Washer, Lock, 1/2-inch 97 457500069 457500007 457500069 Hinge Assembly, right hand 18 457500070 457500008 457500070 Hinge Assembly, left hand 19 657012641 657012641 Cap Screw, Hex Head, 1/2-13 by 1-3/4 129 657012641 Cap Screw, Hex Head, 1/2-13 by 1-3/4 16

10 679033107 679033107 Washer, Lock, 1/2-inch 1210 679033107 Washer, Lock, 1/2-inch 1611 643023007 643023007 Nut, Hex, 1/2-13 1211 643023007 Nut, Hex, 1/2-13 1612 621012271 621012271 621012271 Screw, Set, Socket, 1/2-13 by 1 413 757160011 757160026 757160011 Pin, Hinge 214 600134000 600134000 600134000 Fitting, Grease, Straight 615 657356334 657356334 657356334 Handle Grip 216 757280017 757280027 757280010 Counterweight and Rod Assembly 217 621012266 621012266 621012266 Screw, Set, Cup Point, 1/2-13 by 1/2 4

continued....


Page 24

Figure 15. Exploded View of Replacement Parts

18

21

20

19

23

22

24


....continued from page 23

Part Number

Ref. Model Model ModelNo. 1018 1016 816 Part Name Qty.

18 257020007 257020001 257020004 Beam 119 757080015 757080056 757080015 Bushing, Slide Pin 220 656164302 600164307 656164302 Ring, Retaining, Slide Pin Bushing 221 457080076 457080009 457080076 Bushing, Eccentric 222 757030041 757030041 757030016 Radius Bar 123 613012131 Screw, Cap, Flathead, 5/16-18 by 3/4 2123 613012131 613012131 Screw, Cap, Flathead, 5/16-18 by 3/4 1724 257090008 257090002 257090005 Bed Assembly 125 757130036 757130036 757130036 Stop Rod, Apron 126 600083604 600083604 600083604 Pin, Clevis 127 600073516 600073516 600073516 Pin, Cotter, 3/32 by 1-inch 128 757160038 757160038 757160038 Stud, Apron Stop 129 757260072 757260072 757260072 Collar, Apron Stop 130 621012125 621012125 621012125 Screw, Apron Stop Collar, 5/16-18 by 5/16 131 666023007 666023007 666023007 Nut, Apron Stop Stud 132 600134006 600134006 600134006 Fitting, Grease, 45 Degree 233 657164324 657164322 657164324 Ring, Retaining 234 757080018 757080052 757080018 Bushing, Lower Toggle Pin 235 757160096 757160089 757160096 Pin, Lower Toggle 236 671023010 671023012 671023010 Toggle Nut, lower 237 657033144 657033145 657033144 Washer, Spring 438 645023010 645023012 645023010 Toggle Nut, Upper 239 757990015 757990028 757990015 Toggle Assembly, Right Hand 140 757990016 757990029 757990016 Toggle Assembly, Left Hand 141 757080009 757080053 757080009 Bushing, Toggle (included with items 39 and 40)42 757030003 757030059 757030003 Clamping Lever, Right Hand 143 757030004 757030060 757030004 Clamping Lever, Left Hand 144 657356334 657356334 657356334 Handle, Grip 245 657245118 657245119 657245118 Bearing, Thrust 246 678033113 Washer, Flat, 1-1/8-inch 247 679033112 679033113 679033112 Washer, Split Lock 248 657000390 657000391 657000390 Collar, Clamping 249 757730005 757730001 757730005 Slide Plate, Right Hand 150 757730006 757730002 757730006 Slide Plate, Left Hand 151 611012410 611012410 611012410 Screw, Clamping 252 678033110 678033110 678033110 Washer, Clamping Screw 253a 657000280 657000280 657000280 Collar* 253b 611012418 611012418 611012418 Screw, Socket Head Cap, 3/4-10 by 3* 253c 600063463 600063463 600063463 Pin, Roll 254 617012266 617012266 617012266 Screw, Set, Socket Head, 1/2-13 by 1/2 2

Page 25* Items 53a and 53b a matched set

For your higher production jobs,Roper Whitney of Rockford ispleased to offer.....

��

Offered in a range of models from 4-feet to 13-feet, and capaci-ties through 1/4 mild steel, the Autobrake 2000 is designed tomeet the needs of job shops, metal roofing contractors, andarchitectural sheet metal fabricators. These CNC metal foldingsystems incorporate automatic gauging, clamping, and pivotbending for versatile, efficient part production. Bending andgauge positioning accuracy allow a wide range of parts to befabricated with repeat precision.

Features of the Autobrake 2000 include:* Precision backgauge with multiple stops for high-speed positioning

of the work material.* Integral material support table allows part production by a single

operator, while reducing fatigue, and improving productivity.* Flange-out pivot bending eliminates dangerous whip of the work piece.* Easy-to-learn CNC controls allows part production the first day of

operation.* Clamping and bending beams driven from both ends provide consistent

bends end-to-end as compared to systems driven from one end only.

01/20/01

MANUAL AND MAINTENANCE MANUAL BENDING BRAKES...

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